Why CNC Broach Tools Online Program Generator Beats Machine-Specific Canned Cycles

Introduction:

CNC Broach Tools has always strived to provide the best solutions for broaching applications, including our innovative online program generator. While machine-specific canned cycles, such as Haas G156 or Okuma G190, are commonly used for CNC operations, there are significant reasons why our customers can benefit more by utilizing the CNC Broach Tools online program generator. In this blog post, we will discuss the key advantages of using our custom solution over traditional canned cycles.

Section 1: Understanding Canned Cycles vs. Custom Programs

Canned cycles are pre-programmed routines built into CNC machines, such as Haas G156 or Okuma G190, designed to simplify standard machining processes. They allow operators to perform repetitive tasks without writing custom G-code for each job, saving time and reducing complexity. However, when it comes to broaching, these cycles—although convenient—can introduce challenges.

While canned cycles offer simplicity, they also allow room for human error, which can be problematic when broaching. Custom programs generated by CNC Broach Tools online g-code program generator are created specifically with carbide cutting tools in mind and it doesn’t allow the insert to drag backwards through a keyway. The program generator also sets limits and warns you if your broaching parameters exceed the max capabilities of the chosen tool. For example, the program generator will warn you when trying to broach a bore which is smaller than the minimum bore of the chosen tool. It will also warn you when trying to broach to a radial depth which exceeds the max limit of the tool.

When creating a broaching program for a CNC mill the program generator will create a program with the proper offset so the work coordinate of the tool can match that of your part. The program generator also suggests a starting point of Z.625 and suggests an ending Z which is at least .125 beyond the end of the material to prevent the Phantom Retraction. These things can easily be missed in a machine canned cycle.

Section 2: Why Canned Cycles May Not Be Ideal for Broaching

Canned cycles have limitations that can make them less than ideal for broaching, especially with tougher materials:

• Room for Human Error: While canned cycles provide a level of control, they still allow room for errors during setup that can affect the quality of the broach. This is especially true for tasks involving different materials or complex geometries.
• Haas G156 Issues: The Haas G156 canned cycle, by default, has a 0.001″ retract. After broaching through the material in the Z-axis, the default program retracts only 0.001″ on the X-axis and pulls the insert backward through the keyway. This might work for soft materials but is not suitable for tougher materials like stainless steel or hardened steel, which could damage the carbide cutting edge when pulling backwards through a keyway
• Okuma G190 Issues: The Okuma G190 canned cycle offers a peck cycle feature, which can lead to significant issues if inadvertently left active. Additionally, the user must select the correct cutting direction using M211 or M212 and the infeed mode using M213 and M214, adding steps where errors can easily occur. Forgetting to fully retract into the bore or mistakenly leaving the peck cycle active can lead to suboptimal broaching results.

Section 3: Advantages of the CNC Broach Tools Online Program Generator

Our online program generator offers several key advantages over machine-specific canned cycles:

• Flexibility: Designed for carbide tools with the proper retracts and includes adjustments for specific machine settings, our generator produces G-code tailored to the unique requirements of broaching, ensuring accuracy and minimizing errors.
• Broach Tool Life:  Programs generated by our online program generator include all of the correct retracts so the user can rest assure that insert doesn’t feed backwards though the keyway. It also reminds the user to set the correct Z start and Z end points to ensure the tool doesn’t retract on X prior broaching completely through the material. This not only improves tool life but also helps to reduce the risk of tool breakage, leading to cost savings.
• Ease of Use: The CNC Broach Tools online program generator makes it easy to generate G-code for different machines, eliminating the need to learn and adapt to the specifics of different canned cycles. Users can produce reliable code without extensive programming knowledge.
• Regular Updates: Unlike static canned cycles, our online program generator is continually updated based on user feedback and industry advancements. This means you always have access to the latest, most efficient broaching programs available.

Section 4: Customer Success Stories

One of our customers, a machine shop in West Chicago Illinois, switched from using a Haas G156 canned cycle to using the CNC Broach Tools online program generator for broaching keyways in 304 stainless. They found that the unmodified G156 Haas code was retracting the tool backwards through the keyway which caused the edges of the insert to chip prematurely. The updated code greatly improved their tool life and allowed their CNC lathe operation to run smoother overall.

Section 5: How to Get Started

Getting started with the CNC Broach Tools online program generator is simple:

1. Visit our website and navigate to the program generator page.
2. Input your machine parameters, select the tool holder, material type, and part dimensions.
3. Feeds and speeds can be found here
4. Generate the G-code and download it to your computer
5. Add any machine specific code to the beginning and end of the exported code (such as tool and offset callout, spindle orientation, etc.)
6. Load the code into your machine and dry run as normal

We also offer tutorials and resources to help you make the most of our program generator. For more information, visit CNC Broach Tools Program Generator.

Conclusion

While machine-specific canned cycles like Haas G156 and Okuma G190 can be convenient, they often allow for errors that can impact broaching quality. The CNC Broach Tools online program generator offers the customization, flexibility, and precision needed for optimal broaching results. By reducing room for human error and optimizing cutting conditions, our generator ensures efficient and effective broaching every time.

Give the CNC Broach Tools online program generator a try for your next broaching job, and experience the difference in quality and ease of use.